Suspended refractory curtain

ABSTRACT

A vertically suspended refractory wall having at least two rows of refractory shapes. Each refractory shape of the upper row has a recess in a bottom portion or a lower portion of the refractory shape. Each refractory shape of the lower row has a head portion or an upper portion that lockingly engages within at least a portion of the recess of the refractory shape of the upper row. The interlocked and vertically suspended refractory wall can be used as refractory curtain, such as within an industrial furnace.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to at least two rows of refractory shapes forminga suspended refractory wall, wherein a head section of a refractoryshape of a lower row engages with a recess within a refractory shape ofan upper row to interlock the upper row with respect to the lower row.

2. Discussion of Related Art

Tongue and groove connections have been used to connect structuralshapes with respect to each other. Known interlocking connections havebeen used to fix the horizontal position of structural shapes, withrespect to each other.

SUMMARY OF THE INVENTION

Vertically aligned refractory shapes can be interlocked with respect toeach other to form a vertically suspended refractory wall. The weight,due to gravity, of lower refractory shapes can be used to apply forcesthat interlock each lower row with respect to a corresponding upper rowof refractory shapes. The assembled and interlocked refractory wall canbe used as a suspended refractory curtain, such as in an industrialfurnace to isolate or separate furnace zones.

In certain embodiments of this invention, a plurality of refractoryshapes form two vertically aligned rows of refractory shapes. A headportion or another suitable upper portion or section of a refractoryshape of the lower row can fit within or be engaged with at least aportion of a recess of a refractory shape of an upper row of refractoryshapes, for example, to lockingly engage the refractory shapes of thelower row and a corresponding upper row.

A refractory wall of two or more rows of refractory shapes can be usedto form a suspended refractory wall. In certain embodiments of thisinvention, the refractory shapes can be constructed or made ofrefractory materials or any other suitable material that can withstandthe different temperature and other operating conditions, for example ofan industrial environment, such as a furnace.

According to this invention, the upper row of refractory shapes can beconnected to or engaged by a suitable structural support, such as asuspension metallic or other casting that is connected to or otherwisesupported by a base structure or other suitable supporting structure.The second row and successive lower rows of refractory shapes can beconnected or attached with respect to each other by engaging the headportion or upper portion of a refractory shape of a lower row with atleast a portion of a recess within a portion, such as a bottom portion,of a refractory shape of an upper row.

The size and shape of a head portion or other upper portion cancorrespond to or have a similar cross sectional shape as a recess of therefractory shapes of the lower row. The shapes can be selected to fillthe entire recess or only a portion of the recess.

In certain embodiments of this invention, the vertically suspendedrefractory wall can have unsupported vertical sides. For example, insome embodiments of this invention it is not necessary to havestructural support or other bucking steel on one or more vertical sidesof the suspended wall structure. Thus, down time and costs can bereduced when installing and/or retrofitting a suspended refractorycurtain of an industrial furnace, according to this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention is explained in view of exemplary embodiments, makingreference to the drawings, wherein:

FIG. 1 is a perspective front view of a plurality of rows or refractoryshapes each including a plurality of refractory shapes interlocked withrespect to each other to form a refractory wall;

FIG. 2 is a perspective view of a refractory shape or refractory brick,according to one embodiment of this invention;

FIG. 3 is a front view of a refractory shape, according to oneembodiment of this invention;

FIG. 4 is a side view of the refractory shape, as shown in FIG. 3;

FIG. 5 is a top view of the refractory shape, as shown in FIG. 3;

FIG. 6 is a bottom view of the refractory shape, as shown in FIG. 3; and

FIG. 7 is a front perspective view of a vertical refractory wallsupported by structure at a head portion or an upper portion of an upperrow of the refractory shapes, according to one embodiment of thisinvention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows refractory wall 20 oriented in a generally verticalposition, particularly with respect to horizontal direction 21.Refractory wall 20 of this invention can be supported with any suitablesupport structure or structural element. For example, U.S. Pat. No.4,638,617, the entire disclosure of which is incorporated into thisspecification by reference, discloses a refractory curtain wall which isvertically suspended from a hanger bracket and/or a tubular member. Anyother structure or structural element can be suitably connected to orattached with respect to refractory wall 20, particularly first row 22of refractory wall 20, to structurally support refractory wall 20.

FIG. 7 shows structure 18 connected, attached and/or mounted withrespect to refractory wall 20. According to this invention, it is alsopossible to support refractory wall 20 from the bottom of refractorywall 20, for example at or below the lowermost row of refractory shapes30. Although FIGS. 1 and 7 show the lowermost row of refractory shapes30 with recesses 38, in other embodiments of this invention, one or morerefractories 30 of the lowermost row can have a closed bottom withoutrecess 38.

As shown in FIGS. 1 and 7, with refractory wall 20 according to thisinvention, it is not necessary to use bucking steel or any other framingor structural element on outer edges 28 and 29 of refractory wall 20.Thus, installation and/or replacement of an entire refractory wall 20 oreven a portion of refractory wall 20 is simplified and morecost-effective as compared to conventional refractory curtain walls thatrequire framing or other structural support at outer edges of the wallstructure.

As shown in FIG. 1, a plurality of refractory shapes 30 form first row22 and a plurality of refractory shapes 30 form second row 24. In someembodiments of this invention, second row 24 is vertically aligned withfirst row 22, such as shown in FIGS. 1 and 7. In other embodiments ofthis invention, additional second rows 24 can be positioned orinterlocked with respect to first row 22 or any other row positionedbelow second row 24. As shown in FIGS. 1 and 7, refractory wall 20comprises more than two rows of refractory shapes 30. Depending upon aparticular design requirement, any other suitable shape and/or size ofrefractory wall 20 can be constructed with any other suitable shapeand/or size of refractory shapes 30 according to this invention.

As shown in FIGS. 2-6, each refractory shape 30 has upper portion 32 andlower portion 36. As shown in FIGS. 2 and 3, flange 34 extends away fromor outward with respect to upper face 33. Any other suitable projectionor structural equivalent to upper portion 32 can be integrated with body31 or can be a separate and connected part or component with respect tobody 31 of refractory shape 30.

In some embodiments of this invention, each refractory shape 30 hasrecess 38 that extends inward or into and from lower face 37 of lowerportion 36.

As shown in FIGS. 1 and 7, at least a portion of upper portion 32 ofeach refractory shape 30 of lower or second row 24 is lockingly engagedwithin at least a portion of a corresponding recess 38 of acorresponding refractory shape 30 of upper or first row 22.

Flange 34 and/or upper portion 32 can have any suitable shape, dimensionand/or design that correspondingly fits within recess 38 to lockinglyengage refractory shape 30 of first row 22 with a correspondingrefractory shape 30 of second row 24.

In some embodiment of this invention, upper portion 32 tightly fitswithin recess 38. In certain embodiments of this invention, refractoryshapes 30 of first row 22 and refractory shapes 30 of second row 24 aretightly fit with respect to each other to form a barrier or to sealrefractory wall 20. For example, refractory wall 20 can be verticallysuspended in an industrial furnace and refractory shapes 30 can fittightly with respect to each other so that upline side 26 of refractorywall 20 is isolated from or sealed with respect to or prevents flow in adesired manner to downline side 27 of refractory wall 20.

In certain embodiments of this invention, within each first row 22adjacent refractory shapes 30 contact or abut each other. Likewise, insecond row 24 and/or any lower row of refractory shapes 30, adjacentrefractory shapes 30 contact each other. As shown in FIGS. 1 and 7,refractory shapes 30 of first row 22 form joint 23 between adjacentrefractory shapes 30. Refractory shapes 30 of second row 24 form joint25 between adjacent refractory shapes 30. As shown in FIGS. 1 and 7, inhorizontal direction 21, joint 23 and joint 25 are offset with respectto each other. In other embodiments of this invention, joint 23 isoffset at a different position with respect to joint 25. In yet otherembodiments of this invention, joints 23 can be aligned with joints 25.

As shown in FIGS. 1 and 7, outer edges 28 and 29 of suspended wall 20are free from any external structural support or other structuralmember. In other embodiments of this invention, structural support canbe added to enhance the structural integrity of refractory wall 20.

In certain embodiments of this invention, upper portion 32 has anoverall rectangular cross section. As shown in FIGS. 1, 3 and 7, upperportion 32 has an overall T-shaped cross section. In other embodimentsof this invention, upper portion 32 can have an overall L-shaped crosssection, a C-shaped cross section, an arcuate cross section or any othersuitably shaped cross section, particularly if the cross-sectional shapecorresponds to or engages with the corresponding shape and/or size ofrecess 38.

In certain embodiments of this invention, when connected with respect toeach other, a plurality of rows 22 and 24 form refractory wall 20 withan overall vertically aligned shape. For example, upline side 26 and/ordownline side 27 of refractory wall 20 can have a relatively flat orplanar overall surface.

As shown in FIGS. 1 and 7, with upper portion 32 engaged within at leasta portion of recess 38 of a corresponding refractory shape 30 of firstrow 22, upper portion 32 interferes with body 31 that forms recess 38,for example to lockingly engage refractory shape 30 of second row 24with respect to refractory shape 30 of first row 22. Any suitable size,shape and/or design of upper portion 32 and/or flange 34 can be used toconnect, attach and/or lockingly engage vertically adjacent refractories30, such as within first row 22 and second row 24.

In some embodiments according to this invention, in order to form arelatively tight fit, upper portion 32 and/or flange 34 of eachrefractory shape 30 has a shape that corresponds to recess 38 ofrefractory shape 30 of first row 22. The corresponding shapes can beused to form a relatively tight fit and thus seal or otherwisesignificantly limit flow from upline side 26 to downline side 27 ofrefractory wall 20.

In other embodiments according to this invention, upper face 33 can havea surface shape that corresponds to the shape of lower face 37, so thatconnected, engaged and/or stacked rows of refractory shapes 30 aresealed with respect to each other or prevent or limit flow acrossrefractory wall 20, particularly from upline side 26 to downline side 27of refractory wall 20.

In some embodiments of this invention, flange 34 has a neck and a head.To lockingly engage two vertically aligned refractory shapes 30, a widthof the head can be greater than a width of the neck. With sucharrangement, such as shown in FIGS. 1 and 7, two or more rows ofrefractory shapes 30 can be stacked with respect to each other in a selfsupporting manner.

Refractory shape 30 of this invention can comprise any other suitablerefractory, refractory brick, refractory block or other similarstructure, such as those used in an industrial furnace or a commercialfurnace operating at a relatively high temperature. The dimensions,shapes and/or proportions of refractory 30 can be varied to accommodateany suitable use of refractory wall 20. Refractory shape 30 can beconstructed from any suitable refractory material, such as refractorymaterials that can withstand relatively high temperatures withoutdegrading or warping. For example, refractory shape 30 can beconstructed of any suitable zircon, fireclay, silica, alumina, chromiteand/or silicon carbide material.

While in the foregoing specification this invention has been describedin relation to certain preferred embodiments thereof, and many detailshave been set forth for purpose of illustration, it will be apparent tothose skilled in the art that the invention is susceptible to additionalembodiments and that certain of the details described herein can bevaried considerably without departing from the basic principles of theinvention.

1. A vertically suspended refractory wall comprising: a plurality ofrefractory shapes forming a first row and a second row verticallyaligned with said first row, each said refractory shape having an upperportion and a lower portion, a flange of each said refractory shapeextending away from an upper face of said upper portion, said refractoryshape having a recess extending inward from a lower face of said lowerportion, and at least a portion of said upper portion of said refractoryshape of said second row lockingly engaged within at least a portion ofsaid recess of said refractory shape of said first row.
 2. A verticallysuspended wall according to claim 1, wherein adjacent said refractoryshapes of said first row contact each other and adjacent said refractoryshapes of said second row contact each other.
 3. A vertically suspendedwall according to claim 1, wherein said refractory shapes of said firstrow and said second row are tightly fit with respect to each other toseal the refractory wall from an upline side to a downline side of thesuspended wall.
 4. A vertically suspended wall according to claim 2,wherein said refractory shapes of said first row and said second row aretightly fit with respect to each other to seal the refractory wall froman upline side to a downline side of the suspended wall.
 5. A verticallysuspended wall according to claim 4, wherein said upper portion has arectangular cross section.
 6. A vertically suspended wall according toclaim 1, wherein said upper portion of said second row engaged withinsaid recess of said refractory shape of said first row vertically alignssaid first row and said second row.
 7. A vertically suspended wallaccording to claim 1, wherein said upper portion has a T-shaped crosssection.
 8. A vertically suspended wall according to claim 1, whereinsaid upper portion has a L-shaped cross section.
 9. A verticallysuspended wall according to claim 1, wherein said refractory shapes ofsaid first row are adjacent each other at a first row joint, saidrefractory shapes of said second row are adjacent each other at a secondrow joint, and in a horizontal direction said first row joint is offsetwith respect to said second row joint.
 10. A vertically suspended wallaccording to claim 1, wherein outer edges of the suspended wall are freefrom an external structural support.
 11. A vertically suspended wallaccording to claim 1, wherein with said upper portion engaged withinsaid recess said upper portion of said refractory shape of said secondrow interferes with a body of said second shape that forms said recess.12. A vertically suspended wall according to claim 1, wherein saidrecess of said refractory shape of said first row and said upper portionof said refractory shape of said second row have a correspondinglyengageable shape.
 13. A vertically suspended wall according to claim 1,wherein an upper face of said upper portion of said refractory shape ofsaid second row has a surface shape that corresponds to said lower faceof said lower portion of said refractory shape of said first row.
 14. Avertically suspended refractory wall comprising: a plurality ofrefractory shapes forming at least two vertically aligned rows, eachsaid refractory shape having an upper portion and a lower portion, eachsaid refractory shape having a recess extending inward from a lower faceof said lower portion, and at least a portion of said upper portion ofsaid refractory shape of a lower row lockingly engaged within at least aportion of said recess of said refractory shape of an upper row.
 15. Avertically suspended wall according to claim 14, wherein said flange hasa neck and a head, and a first width of said head is greater than asecond width of said neck.
 16. A vertically suspended wall according toclaim 14, wherein with said upper portion engaged within said recesssaid upper portion of said refractory shape of said lower row interfereswith a body of said refractory shape of said upper row that forms saidrecess.
 17. A vertically suspended wall according to claim 14, whereinsaid refractory shapes of said first row and said second row are tightlyfit with respect to each other to seal the refractory wall from anupline side to a downline side of the suspended wall.